Systems and methods for efficiently exchanging end effector tools

ABSTRACT

A method is disclosed of changing a tool on a programmable motion device. The method includes the steps of moving an attachment portion of an end effector of the programmable motion device in a continuous motion; while the attachment portion of the end effector moves in the continuous motion, engaging one of: the attachment portion of the end effector with the tool, or the tool attached to the attachment portion of the end effector with an exchange system, and continuing to move the attachment portion of the end effector in the continuous motion to change a connection status of the attachment portion of the end effector while the attachment portion of the end effector moves in the continuous motion.

PRIORITY

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 62/739,562 filed Oct. 1, 2018, as well as to U.S.Provisional Patent Application Ser. No. 62/711,087 filed Jul. 27, 2018,the disclosures of which are hereby incorporated by reference in theirentireties.

BACKGROUND

The invention generally relates to programmable motion systems andrelates in particular to end effectors for programmable motion devices(e.g., robotic systems) for use in object processing such as objectsortation.

End effectors for robotic systems may be employed, for example, incertain applications to select and grasp an object, and then move theacquired object very quickly to a new location. Such end effectorsshould be designed to quickly and easily select and grasp an object froma jumble of similar or dissimilar objects, and should be designed tosecurely grasp an object during movement. Certain end effectors, whenused on different objects of different physical sizes, weights andmaterials, may have limitations regarding how securely they may grasp anacquired object during rapid movement, particularly rapid accelerationand deceleration (both angular and linear).

Many end effectors employ vacuum pressure for acquiring and securingobjects for transport and/or subsequent operations by articulated arms.Other techniques for acquiring and securing objects involveelectrostatic attraction, magnetic attraction, needles for penetratingobjects such as fabrics, fingers that squeeze an object, hooks thatengage and lift a protruding feature of an object, and collets thatexpand in an opening of an object, among other techniques. Typically,end effectors are designed as a single tool, such as for example, agripper, a welder, or a paint spray head, and the tool is typicallydesigned for a specific set of needs.

In many applications, it is desirable for the programmable motion deviceto change tools automatically. For that purpose there are automatic toolchangers, such as those offered by ATI Industrial Automation, Inc. ofApex North Carolina and Schunk GmbH & Co. of Germany (each of which usesradially locking bearings). Available tool changers are generallydesigned to accommodate a wide range of applications, including thosewhere the tools may be complex, bulky, or heavy. Some tools may alsorequire pass-through passages for compressed air, electrical signals, orvacuum. The tool changer might also provide rigid high-precisionmounting of the tool on the end effector, so that the robot's load andprecision specifications will not be compromised.

Tool changers also generally require tool racks that hold the tools andfacilitate the mounting and dismounting of tools from the end effector.The tool changers and tool racks generally assume that dismountingoccurs by moving the tool into the rack, engaging the tool by the rack,actuating a latch mechanism to release the tool, and then moving the endeffector away from the tool. Mounting a tool reverses this process—theend effector moves to match the two halves of the tool change device,the tool is released by the rack, the latch is actuated, and the endeffector then moves the tool out of the rack. These mounting anddismounting motions are generally precise and slow, in accord with theprecise tolerances of the tool changer.

A disadvantage of commercially available tool changers is that they areslow. The introduction of long delays can reduce the value of anautomated solution, in some cases to the point that the automatedsolution is not viable. Thus there is a need for tool changing devicesthat achieve greater speed, and an opportunity to achieve that speed bydesigning tool changers for those applications with more liberalrequirements. There remains a further need therefore, for end effectorsystems that permit programmable motion systems to quickly andefficiently change end effector tools.

SUMMARY

In accordance with an embodiment, the invention is directed to a methodof changing a tool on a programmable motion device. The method includesthe steps of moving an attachment portion of an end effector of theprogrammable motion device in a continuous motion; while the attachmentportion of the end effector moves in the continuous motion, engaging oneof: the attachment portion of the end effector with the tool, or thetool attached to the attachment portion of the end effector with anexchange system, and continuing to move the attachment portion of theend effector in the continuous motion to change a connection status ofthe attachment portion of the end effector while the attachment portionof the end effector moves in the continuous motion.

In accordance with another embodiment, the invention is directed to amethod of exchanging a tool on a programmable motion device. The methodincludes the steps of moving an attachment portion of the end effectorin a continuous motion, removing a first tool from the attachmentportion of the end effector while the attachment portion of the endeffector moves in the continuous motion, and attaching a second tool tothe attachment portion of the end effector while the attachment portionof the end effector device moves in the continuous motion. In accordancewith yet another embodiment, the invention is directed to a method ofchanging a tool on a programmable motion device. The method includes thesteps of moving an attachment portion of an end effector of theprogrammable motion device in a linear motion, while the attachmentportion of the end effector moves in the linear motion, engaging one of:the attachment portion of the end effector with the tool, or the toolattached to the attachment portion of the end effector with an exchangesystem, and continuing to move the attachment portion of the endeffector in the linear motion to change a connection status of theattachment portion of the end effector while the attachment portion ofthe end effector moves in the linear motion.

In accordance with a further embodiment, the invention is directed to asystem for changing a tool on a programmable motion device. The systemincludes an engagement system for moving an attachment portion of an endeffector of the programmable motion device in a continuous motion, andwhile the attachment portion is moving, engaging the tool with one of anattachment portion of the end effector, or an exchange station tothereby change a connection status of the attachment portion of the endeffector while the attachment portion of the end effector moves in thecontinuous motion.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description may be further understood with reference tothe accompanying drawings in which:

FIGS. 1A and 1B show illustrative diagrammatic views of an end effectorof a programmable motion device disengaging a first tool (FIG. 1A) andengaging a second tool (FIG. 1B);

FIGS. 2A-2E shows illustrative diagrammatic detailed views of the endeffector of FIGS. 1A and 1B moving toward a disengagement station (FIG.2A), moving the end effector away from the disengagement station (FIG.2B), leaving the first tool and moving the end effector toward a secondtool (FIG. 2C), moving the end effector toward the second tool (FIG.2D), and engaging and removing the second tool (FIG. 2E) in accordancewith the prior art;

FIGS. 3A and 3B show illustrative diagrammatic views of an end effectorof a programmable motion device disengaging a first tool (FIG. 3A) andengaging a second tool (FIG. 3B) in accordance with an embodiment of thepresent invention;

FIG. 4 shows an illustrative diagrammatic view of a programmable motiondevice system including a system for changing end effector tools inaccordance with an embodiment of the present invention;

FIG. 5 shows an illustrative diagrammatic view of an image from aprimary perception system of the system of FIG. 4 showing a view into abin with grasp locations overlaid on the image;

FIG. 6 shows an illustrative diagrammatic view of a secondary perceptionsystem of the system of FIG. 4 showing a plurality of secondaryperception units;

FIG. 7 shows an illustrative diagrammatic view of a programmable motiondevice for use in a system in accordance with another embodiment of thepresent invention that includes an acquisition unit and coupling systemthat includes a linear force accommodation system;

FIG. 8 shows an illustrative diagrammatic enlarged view of the endeffector of the system of FIG. 7;

FIG. 9 shows an illustrative diagrammatic exploded view of an endeffector system of a programmable motion device in accordance with anembodiment of the present invention;

FIG. 10 shows an illustrative diagrammatic view of the end effectorincluding the tool of FIG. 9 diagrammatically the attractive magneticforce between the components;

FIG. 11 shows an illustrative diagrammatic view of the end effectorsystem of FIG. 9 with the components connected showing the vacuumpassing therethrough;

FIG. 12 shows an illustrative diagrammatic view of the end effectorsystem of FIG. 9 with a vacuum engaging an object;

FIG. 13 shows an illustrative diagrammatic view of the end effectorsystem of FIG. 9 showing a removal force overcoming the vacuum force;

FIG. 14 shows an illustrative diagrammatic view of an end effectorsystem in accordance with another embodiment that includes anelectromagnet;

FIGS. 15A and 15B show illustrative diagrammatic side views of the endeffector system of FIG. 14 with the components connected (FIG. 15A) andwith the components not connected (FIG. 15B);

FIG. 16 shows an illustrative diagrammatic view of an end effector toolexchange device in accordance with an embodiment of the presentinvention that includes rollers;

FIGS. 17A-17D show illustrative diagrammatic views of an end effectorexchange system including multiple end effector tool exchange devices,wherein a first end effector tool is received by a first exchange device(FIG. 17A), the first end effector tool is disengaged from the endeffector (FIG. 17B), the end effector then engages a second end effectortool (FIG. 17C), and the end effector is then coupled to the second endeffector tool (FIG. 17D);

FIG. 18 shows an illustrative diagrammatic view of an end effectorexchange device in accordance with another embodiment of the presentinvention involving sets of engagement wheels;

FIGS. 19A-19D show illustrative diagrammatic views of an end effectorexchange system including multiple end effector exchange devices inaccordance with another embodiment of the present invention, wherein afirst end effector tool approaches a first exchange device (FIG. 19A),the first end effector tool is engaged by the exchange system (FIG.19B), the end effector tool disengages from the end effector (FIG. 19C),and the end effector tool becomes fully disengaged from the end effector(FIG. 19D);

FIGS. 20A and 20B show illustrative diagrammatic views of an endeffector exchange system including multiple end effector exchangedevices in accordance with a further embodiment of the presentinvention, wherein an end effector having a first end effector toolapproaches a first exchange device (FIG. 20A) from which it isdisengaged, and the end effector later engages a second end effectortool (FIG. 20B);

FIG. 21 shows an illustrative diagrammatic view of an end effectorexchange device in accordance with another embodiment of the presentinvention that involves non-linear motion of the end effector;

FIGS. 22A-22D show illustrative diagrammatic views of an end effectorexchange system including multiple end effector exchange devices inaccordance with a further embodiment of the present invention involvinga single exchange device, wherein a first end effector tool approaches afirst exchange device (FIG. 22A), the first end effector tool is engagedby the exchange system (FIG. 22B), the end effector tool disengages fromthe end effector (FIG. 22C), and the end effector tool becomes fullydisengaged from the end effector (FIG. 22D);

FIGS. 23A-23D show illustrative diagrammatic views of an end effectorexchange system including multiple end effector exchange devices inaccordance with yet a further embodiment of the present inventioninvolving a single track, single exchange device, wherein a first endeffector tool approaches a first exchange device (FIG. 23A), the firstend effector tool is engaged by the exchange system (FIG. 23B), the endeffector tool disengages from the end effector (FIG. 23C), and the endeffector tool becomes fully disengaged from the end effector (FIG. 23D);

FIGS. 24A and 24B show illustrative diagrammatic views of a portion ofan end effector exchange system that includes an end effector advancingmechanism;

FIG. 25A shows an illustrative diagrammatic view of an end effector thatincludes a non-magnetic coupling for attaching to an end effector tool;

FIG. 25B shows an illustrative diagrammatic side view of the endeffector of FIG. 25A;

FIG. 25C shows an illustrative diagrammatic side sectional view of theend effector of FIGS. 25A and 25B coupled to the end effector tool;

FIG. 26A shows an illustrative diagrammatic view of an end effector thatincludes a non-magnetic coupling that includes balls in sockets forattaching to an end effector tool;

FIG. 26B shows an illustrative diagrammatic side view of the endeffector of FIG. 26A;

FIG. 26C shows an illustrative diagrammatic side sectional view of theend effector of FIGS. 26A and 26B coupled to the end effector tool;

FIG. 27A shows an illustrative diagrammatic view of an end effector thatincludes a non-magnetic friction fit coupling for attaching to an endeffector tool;

FIG. 27B shows an illustrative diagrammatic side view of the endeffector of FIG. 27A;

FIG. 27C shows an illustrative diagrammatic side sectional view of theend effector of FIGS. 27A and 27B coupled to the end effector tool;

FIG. 28 shows an illustrative diagrammatic view of an end effectorsystem that includes an attachment mechanism connected to the endeffector tool;

FIGS. 29A-29D show illustrative diagrammatic side views of the endeffector and tool of FIG. 28 approaching (FIG. 29A) an end effector toolexchange system and entering (FIG. 29B) the end effector tool exchangesystem, disengaging the end effector tool (FIG. 29C), and leaving theend effector tool with the end effector tool exchange system (FIG. 29D);

FIGS. 30A-30D show illustrative diagrammatic side views of the endeffector of FIG. 28 approaching (FIG. 30A) an end effector tool exchangesystem and engaging (FIG. 30B) an end effector tool, coupling to the endeffector tool (FIG. 30C), and leaving the effector tool exchange systemwith the end effector tool (FIG. 30D);

FIG. 31 shows an illustrative diagrammatic view of an end effectorsystem in accordance with a further embodiment of the present inventionengaging a bracket;

FIG. 32 shows an illustrative diagrammatic side view of the end effectorsystem of FIG. 31;

FIGS. 33A-33E show illustrative diagrammatic side views of the endeffector system of FIG. 31 disengaging an end effector tool using thebracket wherein the end effector and tool approach the bracket (FIG.33A), engage the bracket (FIG. 33B), begin to disengage the tool (FIG.33C), further disengage the tool (FIG. 33D), and become separated fromthe tool (FIG. 33E);

FIGS. 34A-34E show illustrative diagrammatic side views of the endeffector system of FIG. 31 engaging an end effector tool using thebracket wherein the end effector approaches the tool held by the bracket(FIG. 34A), begins to engage the tool (FIG. 34B), further engages thetool (FIG. 34C), fully engages the tool (FIG. 34D), and carries toattached tool away from the bracket (FIG. 34E);

FIG. 35 shows an illustrative diagrammatic side sectional view of theend effector system of FIG. 31 showing the insertion depth;

FIG. 36 shows an illustrative diagrammatic view of an end effectorsystem in accordance with another embodiment of the present inventionthat includes a separated end effector and tool with a rotationalengagement/disengagement exchange system;

FIG. 37 shows an illustrative diagrammatic view of the end effectorsystem of FIG. 36 that includes end effector and tool coupled togetherwith a rotational engagement/disengagement exchange system;

FIG. 38 shows an illustrative diagrammatic side view of the system ofFIG. 36;

FIG. 39 shows an illustrative diagrammatic side view of the system ofFIG. 37;

FIGS. 40A-40F show illustrative diagrammatic views of an end effectorand tool approaching the exchange system of FIG. 36 (FIG. 40A),initially engaging the exchange system (FIG. 40B), further engaging theexchange system (FIG. 40C), beginning to separate the end effector toolfrom the end effector (FIG. 40D), further separating the end effectortool from the end effector (FIG. 40E), and showing the end effector toolseparated from the end effector;

FIGS. 41A-41F show illustrative diagrammatic top views of the endeffector and tool approaching the exchange system of FIG. 36 (FIG. 41A),initially engaging the exchange system (FIG. 41B), further engaging theexchange system (FIG. 41C), beginning to separate the end effector toolfrom the end effector (FIG. 41D), further separating the end effectortool from the end effector (FIG. 41E), and showing the end effector toolseparated from the end effector (FIG. 41F);

FIGS. 42A-42F show illustrative diagrammatic side views of the endeffector and tool approaching the exchange system of FIG. 36 (FIG. 42A),initially engaging the exchange system (FIG. 42B), further engaging theexchange system (FIG. 42C), beginning to separate the end effector toolfrom the end effector (FIG. 42D), further separating the end effectortool from the end effector (FIG. 42E), and showing the end effector toolseparated from the end effector (FIG. 42F);

FIG. 43 shows an illustrative diagrammatic top view of a programmablemotion system including a end effector exchange system in accordancewith an embodiment of the present invention;

FIGS. 44A and 44B show illustrative diagrammatic views of an endeffector tool exchange system in accordance with an embodiment of thepresent invention that includes a plurality of exchange devices with theend effector approaching with a first tool (FIG. 44A) and leaving with adifferent second tool (FIG. 44B);

FIG. 45 shows an illustrative diagrammatic view of an end effectorexchange system for use with a rotational movement of the end effector;and

FIG. 46 shows an illustrative diagrammatic side view of the end effectorexchange system of FIG. 45 showing the rotational movement of the endeffector.

The drawings are shown for illustrative purposes only.

DETAILED DESCRIPTION

Applicants have discovered that there are many applications where toolsare considerably simpler and lighter than those used on certainprecision manufacturing programmable motion systems, and further, thatin such other applications, the requirements on the tool-changer may berelaxed. For example, in some logistics applications, such as processingitems for shipping or E-commerce order fulfillment, it may be necessaryto change vacuum cups from one size to another. A typical vacuum cuprequires no pass-throughs of electrical, pneumatic, or hydraulicpassages, other than the vacuum. Further, the precision of the mountneed not be high. Even in a manufacturing application, there are caseswhere the tools to be exchanged are simple and the requirements for thetool changer may be relaxed.

In programmable motion devices it is sometimes desirable to change endeffector tools during processing (between moving objects). The processof changing end effector tools may generally involve (with reference toFIG. 1A) moving an end effector 10 of a programmable motion device thatcontains a tool 12 toward a storage area 14. The storage area 14 mayalso include another tool 16 that may be retrieved in place of the endtool 12, as shown in FIG. 1B. The process, however, of exchanging thetool 12 for the tool 16 may require considerable steps.

For example (and with reference to FIGS. 2A-2E), the process mayinvolve, at least, moving the attachment portion 10 of the effector thatcontains the attached tool 12 in a first direction as generally shown atA in FIG. 2A. The process may later involve moving the attachmentportion 10 of the effector in a second direction as generally shown at Bin FIG. 2B once the first tool 12 is released from the attachmentportion 10 of the effector. The process may then involve moving theattachment portion 10 of the effector in at least two further directionsas generally shown at C and D in FIG. 2C. Finally, the process mayinvolve again changing directions, and moving the attachment portion 10of the effector in a direction as generally indicated at E in FIG. 2D,until the attachment portion 10 reaches a position at which it is readyfor further processing.

Such a typical tool change motion, therefore, involves fine verticalin-and-out motions to dismount tool 12, and further fine verticalin-and-out motions to mount tool 16. Each fine motion includes areversal, and there is a further reversal between the mount and dismountmotions, so the process involves multiple reversals and fine motions,leading to a very time consuming operation. The arrangement is typicalbut not universal. In some cases the approaching motion might behorizontal, and the departing motion vertical, or vice versa. Eventhough such a motion is not a reversal, it presents the same problems.The path includes a sharp corner, which can only be produced by comingto a stop or a near-stop, which is a time-consuming fine motion.

Not only does the above process described with reference to FIGS. 2A-2Einvolve many changes of direction as well as fine motion control, theprocess also involves many steps of disengaging/engaging the tool 12 andthe tool 16 both from/to the attachment portion 10 of the effector, aswell as to/from the storage area 14 while the effector is stopped. Forexample, the tool 12 must be disengaged from the attachment portion 10,and engaged by the storage area 14 as shown in FIG. 2B. The process mayalso involve disengaging the tool 16 from the storage area 14 andengaging the tool 16 by the attachment portion 10 of the effector asshown in FIG. 2D.

The process of changing tools of the effector of the programmable motiondevice therefore involves many changes in direction of the effector, aswell as many complex fine control engagement and disengagement steps ofthe tools 12, 16 from and to the attachment portion 10 of the effectorand the storage area 14.

The exchanging system in accordance with various embodiments of thepresent invention (and with reference to FIGS. 3A and 3B) may, forexample, be used with a programmable motion system for moving objectsfor processing, such as sortation and order fulfillment. The exchangesystem 50 includes an exchange device 52 that may contain an endeffector tool 54. When an attachment portion of the effector 56 of aprogrammable motion device moves in a direction as indicated at F inFIG. 3A, an end effector tool 58 that is attached to the attachmentportion of the effector 56 will become detached from the attachmentportion of the effector, and in its place, the end effector tool 54 willbecome attached to the attachment portion effector 56 as shown in FIG.3B, all while the attachment portion moves in the direction as shown atF. In various embodiments, the movement may be linear and/or may becontinuous. As shown in FIGS. 3A and 3B, the effector moves through aserial pair of holders. As it passes through the first half, the presenttool 58 is dismounted. As it passes through the second half, the newtool 54 is mounted.

The invention generally provides a set of mechanisms and methods toachieve a rapid exchange of tools in various embodiments. Previous toolexchange devices require the programmable motion device to make at leasttwo fine motions, meaning slow and precise motions. The first finemotion approaches the holder and dismounts the present tool. The secondfine motion approaches and mounts the desired tool.

The invention eliminates the fine motions of the programmable motiondevice. Instead, the programmable motion device, including the effector,remains in substantially uniform motion, and the tool-unmounting andtool-mounting motions are accomplished relative to the effector, as itflies by the holder. The term tool refers to the removable part of thesystem that is to be exchanged. The term effector refers to the distallink of the programmable motion device, on which the tool is mounted.The term holder refers to the mechanism that holds a tool andfacilitates the tool exchange process. The term rack refers to severalholders arranged as a unit to hold a variety of tools for selection bythe programmable motion device.

The multiple tools and the exchanging system of certain embodiments ofthe invention may be used with a wide variety of programmable motiondevices that are employed for a variety of purposes, such as, forexample, object order fulfillment, or object sortation for materialshandling and shipping.

The tool change systems of the invention may be used with a wide varietyof programmable motion systems and applications. The systems andapplications disclosed herein, are in no way limiting of the systems andapplications that may benefit from the invention. In applications suchas order fulfillment for example, objects are collected intoheterogeneous sets and need to be processed into appropriate groupings.In particular, individual objects need to be identified (e.g., byperception systems) and then routed to object-specific locations. Thedescribed system reliably automates the grasping and movement of suchobjects by employing both a robotic arm and versatile gripping systems.The perception units (e.g., cameras or scanners) may look for a varietyof codes such as indicia, e.g., barcodes, QR codes, radio frequencytags, Stock Keeping Unit (SKU) codes, Universal Parcel Codes (UPC), lowwavelength IR (LWIR), as well as invisible barcodes and digitalwatermarks such as Digimarc DWCode, etc. Sorting for order fulfillment,for example, is one application for automatically identifying objectsfrom a heterogeneous object stream. Barcode scanners have a wide varietyof uses including identifying the Stock Keeping Unit of an article, ortracking parcels.

Such an order fulfillment system automates part of the sorting processin conjunction with a robotic pick and place system, and in particular,the step of grasping and carrying objects. A programmable motion devicesuch as a robotic arm, for example, picks an object from a bin, placesthe object in front of (or drops an object into) a scanner, and then,having obtained identification information for the object (such as abarcode, QR codes UPC codes, other identification codes, informationread from a label on the object, or size, weight and/or shapeinformation), routes the object toward the appropriate bin or shelflocation by either moving the object itself, or placing the object in oron a conveyance system. Since certain scanners employ cameras or lasersto scan 1D or 2D symbologies printed on labels affixed to objects, thebarcodes must be visible to the scanner's sensors for successfulscanning in order to automatically identify items in a heterogeneousstream of arbitrary objects, as in a jumbled set of objects found in abin. Further applications for grasping systems of the invention includesortation for a wide variety of applications, including orderfulfillment, collection of objects for shipping, and collection ofobjects for inventory purposes etc.

An important aspect is the ability to identify identification or mailinginformation for the object (such as a barcode, QR codes UPC codes, otheridentification codes, information read from a label on the object, orsize, weight and/or shape information) of objects by employing aprogrammable motion device such as a robot arm, to pick up individualobjects and place them in front of one or more scanners or to drop orplace the object into a scanner. In accordance with other embodiments,the programmable motion device may include a parallel arm robot(Delta-type arm) or a linear indexing pick and place system. Certainconvention scanning systems, for example, may be unable to see labels orbarcodes on objects that are presented in a way that this information isnot exposed or visible. Tool changing systems of the invention may beused with programmable motion devices such as articulated arms, parallelarm robots (Delta-type arms), or linear indexing pick and place systems.

Important components of an automated processing system that includes atool changing system of the invention are shown in FIG. 4. FIG. 4 showsa programmable motion system 60 that includes an articulated arm 62 thatincludes an end effector 64 having a tool 72 and articulated sections66, 68 and 20. The end effector 64 is able to access a tool changingsystem 52, and the invention provides that the end effector may changetool 72 for another tool, e.g., 73, by moving through the tool changingsystem 52 as discussed in more detail below.

Generally, the articulated arm 62 selects objects from an input areasuch as a conveyor 22 that are either in a bin on the conveyor 22, orare on the conveyor itself. A stand 24 includes an attached perceptionunit 26 that is directed toward the conveyor from above the conveyor 22.The perception unit 26 may include, for example, a 2D or 3D camera, or ascanner such as a laser reflectivity scanner or other type of bar-codereader, or a radio frequency ID scanner. The perception unit 26 ispositioned to acquire perception data regarding objects that areprovided on a conveyor 22 or in a bin that is on the conveyor 22. Basedon the perception data, the system 60 determines one or more grasplocations in an object, and directs the end effector 64 on thearticulated arm 62 to grasp the object.

Images taken by the perception unit 26 may be displayed on a touch inputscreen 28 so that persons in the environment may interact with thesystem 60, e.g., by confirming, rejecting or proposing, possible grasplocations on objects, based on which the system 60 may undergo machinelearning (e.g., in processor 34) with regard to the objects. FIG. 5, forexample, shows objects 40-47 in a bin 48 on the conveyor 22. Associatedwith each object are possible grasp locations and orientations that thegripper may use to grasp the objects. While certain grasp locations 49are good, others, such as 59 are not good grasp locations for a varietyof reasons, such as for example, that the object is presently blocked byother objects. Either with or without prompts, a human may enterinformation through the interactive touch input screen regarding whichgrasp locations proposed by the system are good, which grasp locationsproposed by the system are bad, and/or which grasp locations notproposed by the system would be advised.

The system 60 provides that when an object has been grasped by the endeffector 64 of the articulated arm 62, the end effector 64 may presentthe object to a perception station 29. As further shown in FIG. 6, theperception station 29 includes a plurality of light sources 31 (e.g.,LEDs, or fluorescent, phosphorescent or incandescent lights), as well asa plurality of perception units 33 (e.g., scanners or cameras) forreading barcodes, radio frequency tags, Stock Keeping Unit (SKU) codes,Universal Parcel Codes (UPC), low wavelength IR (LWIR) information orinvisible barcodes and digital watermarks. While the perception unit 26may have detected any such label or code upon grasp planning if thelabel or code was facing the perception unit 26, the additionalperception units 33 at the perception station 29 provide views of allremaining sides of the object when the end effector 64 positions theobject within the perception station 29.

Having identified a code or indicia, the processing system 34 then pullsrouting information regarding the object, and the articulated arm 62then moves the object using the end effector 64 to an appropriatelocation 32 of a bank of sortation locations 30. The end effector 64further includes an acquisition unit tool 72 (such as a vacuum unit,e.g., a vacuum cup) for contacting and grasping the objects. In anembodiment, the acquisition unit tool 72 may be in the form of aflexible bellows, and may include a vacuum line 80 attached to the endeffector 64 for providing a vacuum source at the mouth of the flexiblebellows.

As further shown in FIGS. 7 and 8, the acquisition unit tool 72 iscoupled to a conduit 84, the other end of which 82 is coupled to thevacuum line 80 (shown in FIG. 4). The conduit 84 is adapted to linearlyslide into and out of an end effector base 85 relatively small amounts.The end effector 64 provides the vacuum through the conduit to theacquisition unit tool 72. The end effector 64 is attached to thearticulated arm via a coupling mechanism 90 that includes clamp arms 92.A slidable anchor 94 is attached to the conduit 84 such that as theconduit 84 slides in and out of the end effector base 85, the anchormoves along a track 96. When the anchor 94 (and the conduit 84) movestoward the base 85, the upper spring 87 is compressed, and then theanchor 94 moves away from the base 85, the lower spring 89 iscompressed. The end effector 64 thereby permits the end acquisition unittool 72 to move toward and away from the base 85 against the forces ofsprings in either direction to accommodate axial forces that are appliedto the acquisition unit tool 72 during use. The coupling mechanism 90includes an attachment plate 95 for coupling to the robotic arm. Thecoupling mechanism may also include a low profile load plate formonitoring load forces on the acquisition unit tool 72.

The system 60 may therefor further provide a plurality of end effectortools in addition to end effector tool 72 that are suited for graspingdifferent objects. In certain embodiments, the end effector tools arevacuum cups that provide passage of a vacuum therethrough. As anexample, the different end effectors may each be a different size, andbe suited for grasping different objects having differently sized flatareas (for grasping).

In accordance with certain embodiments, therefore, the inventionprovides a programmable motion system including a dynamic end effectorsystem. The dynamic end effector system includes a plurality ofacquisition units and coupling means. The plurality of acquisition toolsare provided at an exchange station within an area accessible by theprogrammable motion device. The coupling means is for coupling any ofthe plurality of acquisition tools to an end effector of theprogrammable motion device such that any of the acquisition tools may beautomatically selected from the exchange station and used by theprogrammable motion device without requiring any activation or actuationby the exchange station and without requiring any intervention by ahuman. While a human may place a new actuation tool into the exchangesystem, and may then inform the system as to which actuation unit isplaced in the system and where it is placed, this is not required. Thesystem may originally be set up such that the system is programmed toknow which actuation tools began in which positions (and thereaftertrack any movement via exchanges). In other embodiments, the vacuum cuptools may have unique physical or magnetic features that may be detectedby the exchange station or by the end effector. The programmable motionsystem may therefore process the objects, and between moving an object,the system may quickly and efficiently exchange a current end effectortool with a new end effector tool as needed.

Systems of certain embodiments of the present invention provide that anacquisition tool, such as a vacuum cup (e.g., a flexible bellows typevacuum cup), through which a high vacuum may be designed to flow, may beexchanged for another vacuum cup during use, by the programmable vacuumdevice. In particular, and with reference to FIG. 9, a high flow vacuummay be provided to flow through an acquisition unit tool 100 from a base110 up through an opening 108. When coupled to an end effector thatincludes a coupling unit 102 (having magnets 104), a collar 106 and aconduit of the end effector 112, the high flow vacuum is maintainedthrough the end effector, and in particular, through the interior 114 ofthe conduit 112. Again, the coupling unit 102 couples the end effector112 to the tool 100 by having the magnetic field created by the magnets104 pull the ferromagnetic top portion 116 of the tool 100 toward thecoupling unit 104, such that the collar 106 of the end effector isengaged within the interior of the acquisition unit tool 100 when thetool 100 is engaged with the end effector 112. Both before and aftercoupling, a high flow vacuum (V_(h)) is permitted to flow through theunits as shown.

The coupling of the different vacuum cups to an end effector via themagnets also presents fewer limitations on the lifting dynamics. Inparticular, and with reference to FIGS. 10-13, The coupling unit 104attached to the conduit 112 is drawn toward the ferromagnetic top 116 ofthe vacuum cup 100 by a magnetic field Fm as shown in FIG. 10. Becausethe object when lifted does not hang from the vacuum cup (but rather isdrawn by the vacuum V_(h)), the strength of the magnetic field is notdetermined by the load of grasping and lifting. In particular, and withreference to FIGS. 11 and 12, the object is lifted by the force of thevacuum (e.g., a high flow vacuum) V_(h), which as discussed above, flowsthrough both the vacuum cup 100 and the conduit 112. It is the vacuumV_(h) that is used to grasp an object 118 as shown in FIG. 12. Althoughthe grasping is not directly reliant on the magnetic field F_(m), thestrength of the magnetic field F_(m) may become a factor if the weightof the object 118 (or its effective movement force due to acceleration)is closely matched to the lifting force created by the vacuum force ofV_(h), to lift the object 118. This is due to atmospheric pressure bothbeing applied to the object and being applied to the vacuum cup (and inparticular to any radially outwardly extending flanges) while a vacuumexists within the cup. Adjusting the strength of the magnetic field mayminimize this. Due to the flared shape of the vacuum cup as showntherefore, there is atmospheric pressure that acts to separate the cupfrom the end effector. Provided the magnetic force suffices to balancethat atmospheric pressure, and the weight and dynamic load of the cup'sinertia, then if the weight of the object is too great for the liftingforce created by the vacuum force of V_(h), then the object is simplynot lifted. Adjusting the shape of the vacuum cup may also help minimizethis, for example, by providing for parallel walled cups or cups thatinclude radially inwardly sloping walls toward the object engagementsurface.

In accordance with further embodiments of the invention, it may bedesirable to design the vacuum cup such that any seal between the cupand an object will become compromised in the event that too large aweight is attempted to be lifted (protecting the magnetic coupling frombeing breached or protecting the articulated arm from overload). Suchvacuum cups may, for example, permit some portions of the cup to open orotherwise break the seal between the cup and the object, therebyreleasing the object from the vacuum cup.

In accordance with an embodiment, the present invention provides alinear dismount motion involving the use of an electromagnet or otheractuator, which provides the motive force, allowing other mechanicalelements in the effector or the holder to constrain the tool motion. Afurther embodiment is shown in FIG. 14 that employs a permanent magnetas an unpowered holding force, combined with an electromagnet which canoverwhelm the permanent magnet's field and release the tool.

In particular, FIGS. 14, 15A and 15B show at 120 an embodiment of thepresent invention that includes an attachment portion of an end effector122 that includes an electromagnet 124. The system 120 also includes atool 126 that includes a permanent magnet 128. Since the magnets arepositioned to have reverse polarity at their interface, when theelectromagnet is energized, the tool 126 is held firmly against theeffector 122 (as shown in FIG. 15A), and when the electromagnet isde-energized, the tool 126 is released from the effector 122 (as shownin FIG. 15B).

In further embodiments, the tool 126 may be held firmly against theeffector 122 without the electromagnet being energized (by virtue of themetal in the electromagnet engaging the permanent magnet 128). Further,the releasing of the tool 126 may be accomplished by actively reversingthe polarity of the electromagnet to push the permanent magnet 128 andthe tool 126 away from the effector 122.

The use of a magnetic attachment between the tool and the end effectormay be employed with a wide variety of tool exchange systems. Further,there are several possible mechanisms to produce the desired relativemotions, such as mechanical constraint, magnetic fields, and variouscombinations. The best combination varies with the nature of the tool,the application, and the mechanism by which the tool is retained on theeffector, whether it be magnetic, a bayonet mount, or some other type.

For example, the tool may include protrusions such as two sets of wheelsfor engaging a fixed exchange holder. FIG. 16 for example, shows anexchange system 130 that includes a holder 132 having a pair of slottedarms 134, and each slotted arm 134 includes a slot 136. Each slotincludes a slot opening, and a deeper interior section 138 into which atool may be dropped. In particular, a gripper assembly 140 that includesan effector 142 to which a tool 144 is attached, may include rollers (orwheels or guides) 146 on the tool 144. When the gripper assembly 140 ispositioned above the section 138, the electromagnet releases (or pushes)the tool 144 away from the effector 142 as discussed above. The effector142 then continues moving between the arms 134 and out of the exchangesystem 130.

Many schemes have been identified to arrange the desired motion of thetool relative to the effector. FIG. 17A-17D show a scheme in which theelectromagnet is employed to drop a tool into, or retrieve a tool from,an exchange station. In further embodiments, the tool motion may occurby being rigidly attached to a mobile part of the holder as discussedbelow.

In particular, and as shown in FIGS. 17A-17D, an effector 142 of agripper assembly moves together with a tool 144. The movement (as shownat G) may be linear, and may be discontinuous or (preferably)continuous. As shown in FIG. 17A, the programmable motion device isconfigured to move the gripper assembly toward the exchange system 130such that the wheels 146 (or guides) are aligned to travel along theunderside of the upper portion of the slot 136. When the effector 142 isabove the deeper interior section 138 the electromagnet releases thetool 144 from the effector 142, and the tool 142 falls (as shown at H)such that the wheels (or guides) 146 catch on the lower portion of theslot 136 as shown in FIG. 17B. The tool 142 is thereby disengaged by theeffector 142 yet is held in the disengaged state by the exchange station132.

The effector 142 then continues to move in the direction as shown at G,and when the effector 142 is positioned above a new tool 164, theelectromagnet is then again energized, and the tool 164 is drawn towardthe effector 142 and drawn along the direction of travel G of theeffector 142. In particular, since the underside of the slot 136 isramped in the direction of travel G, the leading edge of the upperportion of the tool 144 becomes raised (as shown in FIG. 17C), andcontacts the effector 142 at a leading edge thereof. The remainingportion of tool 144 then quickly engages with the effector 142 as shownat I. The tool 144 becomes attached to the effector 142 for graspingpurposes as discussed above as shown in FIG. 17D.

FIG. 18 show another system 170 in accordance with another embodiment ofthe invention. The system 170 includes an exchange device 172 thatincludes a pair of slotted arms 174, each including an elongated slot176, one section of which 178 is curved downward. A gripper assembly 180that includes an effector 182 to which a tool 184 is attached, includerollers (or wheels or guides) 186 on the tool 184. When the gripperassembly 180 moves the tool 184 through the exchange device 172 in adirection as shown at J, the rollers 186 enter and are guided by theslot 176. When the rollers 186 are guided through the curved section178, the tool 184 is pulled off of the effector 182. The effector 182then continues moving between the arms 174 and out of the exchangesystem 170.

Again, the tool has two pairs of guide wheels that engage a curving sloton the holder. The holder is fixed. As the effector moves through theholder, the curving slot forces the tool to tilt downward, releasing itfrom the effector. The motion to mount the tool would be the reverse.Additional mechanisms may be provided to ensure that the tool completesits travel and releases cleanly from the effector. This embodiment isshown in further detail in FIGS. 19A-19D. In this scheme, the tool'sseparation is forced by contact with the holder, but the holder isimmobile.

In particular, FIG. 19A shows the gripper assembly moving toward theexchange device 172 in the direction J such that the wheels 186 alignwith the slots 176 of the slotted arms 174 of the exchange device 172.FIG. 19B shows the gripper assembly wheels 186 entering into the slot176. As shown in FIG. 19C, when the wheels 186 are pulled downward bythe curved section 178, the tool 184 is pulled away from the effector182. As shown in FIG. 19D, the effector 182 continues to move in thedirection J, and is thereafter free of the tool 184, which remains withthe exchange device 172.

While certain tool and effector attachments may be provided bymechanical coupling (as discussed below with reference to FIGS.25A-30D), in the case of a magnetic coupling, the holder applies amagnetic field that pulls off the tool off of the effector which remainsin a fixture just below the effector, as the effector moves on. Themounting operation uses a reverse motion and the magnetic field is usedto pull the tool and/or effector toward one another. The magnetic fieldis produced by a combination of permanent magnets and electromagnets,any of which may be mounted on the tool, the effector, or the holder, asin the embodiment shown in FIG. 14. A magnetic shunt may also be used incombination with a permanent magnet.

The mounting of a tool onto an effector may be achieved by moving theeffector in the reverse direction. In particular, and with reference toFIGS. 20A and 20B, the gripper assembly 180 moves in the direction asindicated at J, and as the gripper assembly moves through the exchangedevice 172, the tool 184 is removed from the effector 182 (as shown inFIG. 20A), and remains with the exchange device 172 (as shown in FIG.20B) as discussed above. As also shown in FIG. 20A, another exchangesystem 190 including another exchange device 192 may be positionedadjacent the exchange device 172 such that the effector 182 will movetoward another tool 204 that is positioned within slots 196 of slottedarms 194 of the exchange device 192. With reference to FIG. 20B, whenthe effector 182 moves over the tool 204, the tool 204 is drawn to theeffector 204 (due to any of the magnetic attachment processes discussedabove where magnetic coupling is employed). While the motion of theeffector 182 is continuous in some embodiments, it need not be linear infurther embodiments.

For example FIG. 21 shows a system 198 in which the gripper assembly 180moves in the direction as indicated at J, and as the gripper assemblymoves through the exchange device 172, the tool 184 is removed from theeffector 182 (as shown in FIG. 20A), and remains with the exchangedevice 172 as discussed above. In the system 198, however, the effector182 may reverse directions (without stopping) as shown at K, and bedirected toward the exchange device 192. As the effector 182 thentravels through the exchange device 192 (as discussed above) in adirection as indicated at L, the effector 182 will engage and becomeattached to the tool 204 (as discussed above).

The use of the separate units 132, 152, 172, 192 permits different tools(and units) to be assembled adjacent one another dynamically duringprocessing. This permits new tools (and units) to be made available by ahuman, such that the programmable motion system may be able to select anewly made available unit. The units may also be releasably securable intheir respective locations, e.g., by locks 188, which may be used in anyof the above and below disclosed systems. Systems may also be employedto track and identify which units (and tools) are located in which of avariety of exchanging locations.

In sum, the embodiments discussed herein illustrate several schemes: thefirst scheme, where the holder is fixed, but still engages the toolmechanically, the second scheme, where the tool is forced from theeffector by a magnetic field, and the third scheme (discussed below),where a mobile element of the holder engages the tool mechanically.Combinations of these schemes are also possible. For example, a magneticfield might be employed to facilitate or actuate the motions of schemeone or scheme two, and exchange devices may employ any combination oftool loading and unloading schemes. The effectiveness of systems of theinvention depend, in part, on how the holders are combined into a rack,and how the rack is placed in the workspace, to minimize the delaysassociated with changing tools.

FIGS. 22A-22D show a pair of tool holders arranged in series and mountedon a single exchange device, to dismount one tool and mount another, allin one motion. The effector 212 arrives with tool 214 mounted thereonand leaves with tool 224 mounted thereon. In particular, the system 200involves the gripper assembly 210 moving in the direction as indicatedat M as shown in FIG. 22A, and as the gripper assembly moves through theexchange device 202, the tool 214 is removed from the effector 212 (asshown in FIG. 22B), and remains with the exchange device 202 (as shownin FIG. 22C) as discussed above. As further shown in FIG. 22D, anotherpart of the exchange device 202 includes another tool 224 in a curvedportion 208 of a slot 206 suspended by wheels 226 such that as theeffector 212 moves toward the tool 224 that is positioned within slots206 of slotted arms 204 (as shown in FIG. 22C), the effector 212 engagesand picks up the tool 224 (as shown in FIG. 22D). The attachment to theeffector 212 is due to any of the magnetic attachment processesdiscussed above, or by mechanical attachment processes discussed below.This serial pair arrangement (as well as the previously discussedsystems with respect to FIGS. 17A-17D, 20A and 20B) provides thefunction illustrated in FIGS. 3A and 3B. In many cases this would be anideal arrangement, requiring no reversals of motion by the effector.

FIGS. 23A-23D show system 230 that involves a gripper assembly 240moving in the direction as indicated at M as shown in FIG. 23A, and asthe gripper assembly moves through the exchange device 232, the tool 214is removed from the effector 242 (as shown in FIG. 22B), and remainswith the exchange device 232 (as shown in FIG. 22C) as discussed above.As further shown in FIG. 23D, another part of the exchange device 232includes another tool 254 in a curved portion 238 of a slot 236suspended by wheels 256 such that as the effector 242 moves toward thetool 254 that is positioned within slots 236 of slotted arms 234 (asshown in FIG. 23C), the effector 242 engages and picks up the tool 254(as shown in FIG. 23D). The attachment to the effector 242 is due to anyof the magnetic attachment processes discussed above, or by mechanicalattachment processes discussed below. This serial pair arrangement (aswell as the previously discussed systems with respect to FIGS. 17A-17D,20A, 20B and 22A-22D) provides the function illustrated in FIGS. 3A and3B.

Again, in certain applications, the effector might need to return to itsoriginal pose after a tool change, so that a reversal of motion isrequired anyway. In that case, the two holders can be mounted inparallel, with the reversal occurring between the dismount and themount, as shown in FIG. 21. A similar arrangement could be mountedvertically, where for some applications it might better suit workspaceconstraints and preferred motions of the programmable motion device.

The zero-reversal embodiments discussed above are well suited to a taskwhere successive tool changes occur in opposite directions, which mightbe described as a reciprocal task motion. For example, if the robotmoves between work area A and work area B, requiring tool A for workarea A, and tool B for work area B, then the rack could be placedbetween the two work areas, and every tool change would be a straightmotion.

In other applications, however, one may wish to have every tool changeoccur in the same direction, e.g., always when passing from work area Ato work area B. Certain of the embodiments discussed above may notsupport that. Half of the tool changes would require a pair of reversalsin order for the effector to fly through the rack in the correctdirection. In certain applications, the exchange devices 202 of FIGS.22A-22D and 232 of FIGS. 23A-23D, may be configured to rotate abouttheir center along a vertical axis. In other applications, the toolitself may be moved from one side of the exchange device to another.

For example, FIGS. 24A and 24B show an embodiment that allows all toolchange motions to occur in the same direction. It is similar to theserial pair of holders discussed above, except that after the toolexchange process has completed, the held tool is advanced from the backholder to the front holder. FIG. 24A shows a possible advancingmechanism, that involves a linkage mechanism 250. In particular, thelinkage mechanism 250 includes an L-shaped bar 252 that is coupled to apair of rotating linkage members 254 that move the L-shaped bar 252against the wheels 246 of the tool 244 to move the tool 244 from a frontcurved portion of the exchange device 232 to a rear curved portion ofthe exchange device 232.

Systems in accordance with various embodiments of the present inventionmay include magnetic coupling of the tool to the end effector asdiscussed above and below, or mechanical coupling of the tool to the endeffector. FIGS. 25A-25C and 26A-26C, and 27A-27C, for example, showthree different embodiments of the present invention that employmechanical coupling. FIGS. 25A, 26A and 27A show isometric views of theparts de-coupled, FIGS. 25B, 26B and 27B show side views of the partsde-coupled, and FIGS. 25C, 26C and 27C show side sectional views of theparts coupled.

FIGS. 25A-25B show an embodiment that uses retaining clips that engage acurved surface. In particular, an effector 260 may include an inwardlycurved surface 264 that may engage a plurality of curved retaining clips266 on a tool 262. The tool 262 may also have a mounting surface 268 onwhich a capture mechanism may be attached as discussed further below. Inaccordance with further embodiments, the effector 260 may includeretaining clips, and the tool 262 may include a curved surface againstwhich the retaining clips may become engaged.

FIGS. 26A-26C show an embodiment that uses spring-biased balls thatengage a curved surface. In particular, an effector 270 may include aninwardly curved surface 274 that may engage a plurality of positionbiased balls 276 (e.g., biased by springs 277) on a tool 272. The tool272 may also have a mounting surface 278 on which a capture mechanismmay be attached as discussed further below. In accordance with furtherembodiments, the effector 270 may include position biased balls, and thetool 272 may include a curved surface against which the position biasedballs may become engaged.

FIGS. 27A-27C show an embodiment that uses a friction fit between aneffector 260 and a tool 262. In particular, an effector 280 may includean inner wall 284 that is designed to engage a flexible seal 286 on atool 282. In particular, the inner wall 284 may have a diameter that isslightly smaller than an outer diameter of the flexible seal 286. Theeffector 280 and the collar portion 287 of the tool 282 may be formed ofa rigid material such as metal, and the seal 286 may be formed of aflexible material such as a plastic that is just flexible enough toconform to the inner wall 284 and form the seal. The tool 282 may alsohave a mounting surface 288 on which a capture mechanism may be attachedas discussed further below. In accordance with further embodiments, theeffector 280 may include a flexible seal, and the tool 282 may includean inner surface against which the seal may become engaged.

FIG. 28 shows the effector 260 and tool 262 of FIGS. 25A-25C with anattachment mechanism 290 attached to the tool 262. The attachmentmechanism 290 includes a plurality of (e.g., four) rollers 292 that arefreely rotatable on axles. The attachment mechanism may be attached toany of the mounting surfaces 268, 278, 288 of the tools 262, 272, 282;the attachment mechanism is shown in FIGS. 28-30D for illustrativepurposes.

FIGS. 29A-29D show the effector 260 disengaging with the tool 262. Inparticular, FIG. 29A shows the effector 260 with the attached tool 262approaching an exchange device 295 similar to the exchange devices ofFIG. 21, wherein the exchange device includes a pair of slotted arms296, each including slots 294 having downwardly sloping portions 298(one such arm is shown in FIGS. 29A-29D). The effector 260 moves in adirection as indicated at L₁ (FIG. 29A), and the rollers 292 on theattachment mechanism 290 become engaged in the slot 294 of the slottedarms 296 (FIG. 29B). The effector 260 continues to move in the lineardirection L₁, and the tool 262 becomes disengaged from the effector 260as the tool enters the downwardly sloping portion 298 (FIG. 29C). Theeffector 260 still continues to move in the linear direction L₁ and thetool 262 remains within the portion 298 of the slots 294 (FIG. 29D).

The process of attaching a different effector 261 to the tool 262 (orattaching the effector 260 to a different tool) may generally beprovided by reversing the direction. In particular, FIG. 30A shows theeffector 261 approaching the exchange device 296 in a linear directionas indicated at L₂. The exchange device 295 may either be turned around(from FIGS. 29A-29D), or the direction L₂ may be opposite the directionL₁. The effector 261 then engages the tool 262 (FIG. 30B), and continuesto move in the direction L₂ while becoming attached to the tool 262(FIG. 30C). The effector 261 then leaves the exchange device 296 withthe tool 262 attached to the effector 261, while still moving in thedirection L₂ (FIG. 30D). The effector may therefore engage a tool whilecontinuously moving in a linear direction, and may disengage a toolwhile continuously moving in a linear direction.

An important component of certain embodiments of the invention is themechanism of the holder that engages the tool and mounts or dismountsthe tool. A further embodiment shown in FIGS. 31-34E uses a tool 304with a waist (shown at W) that engages a bracket 312 that is part of theholder. FIG. 31 shows the tool 304 and bracket 312 in an oblique view.FIG. 32 shows the tool 304 and bracket 312 in a side view. The tool 304is a vacuum cup mounted on a cylindrical body, with a waist 308 circlingthe cylinder. The tool 304 has a detent groove 308 that engages detentballs 307 on the bracket 312. In FIG. 31, the bracket 312 is horizontal,as if the detent balls 307 are about to engaged the groove 308. In FIG.32, the bracket 312 has tilted and the detent balls 307 have settledinto the detent groove 308. The bracket 312 includes arm portions 306 onwhich the detent balls 307 are provided, as well as a bracket roller310, which engages the waist Was the tool moves toward the bracket 312.

During the tool-dismounting process, the bracket's motion is constrainedto force the phases, as shown in FIGS. 33A-33E. First, the tool 304slides into the bracket (as shown in FIG. 33A), with small correctivemotions occurring by a passive suspension mechanism. The bracket roller310 settles into the waist (as shown in FIG. 33B). As the effector 302and tool 304 continue forward, the bracket 312 pivots about a bracketpivot 314 and the arm portions 306 of the bracket pivot about thebracket roller 310 until the detent balls 307 engage the detent groove308 (as shown in FIG. 33C), so that the bracket is firmly attached tothe tool 304. As the effector 302 continues to move in a straight line(as shown at P), the bracket 312 and tool 304 move as a coupled unit,pivoting about the bracket pivot 314 (as shown at R), where the trailingedge of the tool 304 is in contact with the effector 302 (as shown inFIG. 33D). Lastly, the bracket 312 reaches the limit of its travel, andthe tool 304 has tilted to the point that the effector 304 continuestraveling in the direction P, while the tool remains behind in theholder (as shown in FIGS. 33A-33D).

The tool-mounting process simply reverses the motion. For example, FIGS.34A-34E show the effector 302 moving toward a new tool 324 (as shown inFIG. 34A), engaging a forward edge of the tool 324 (as shown in FIG.34B), and then rotating the bracket 312 about the bracket pivot 314 (asshown at R in FIGS. 34C and 34D). The force of the forward motion P ofthe tool 324 then urges the detent balls 307 to become released from thegroove 308 and the arm portions 306 pivot about the bracket roller 310(as shown in FIG. 34D) to release the tool 324 from the bracket 312. Theeffector 302 then continues moving in the direction P with the new tool324 attached thereto (as shown in FIG. 34E).

It is generally important that the contact forces between the tool andthe effector be small to facilitate a smooth uninterrupted motion of theeffector. In some embodiments, including the embodiment shown in FIGS.31-34E, it is also important that the mechanism ensures a positivecontact force between the tool and the effector, to ensure full travelof the bracket and a clean release of the tool. All of these areaddressed by adjusting parameters of the design, and through passive oractive elements. The bracket-constraining mechanism as shown can bemodeled as two four-bar linkages, but there are many different designsfor constraining the motion of the bracket.

Many of the embodiments discussed above assume a shallow insertion depthof the effector in the tool. FIG. 35 shows a sectional view of this,where the end 320 of the effector 302 (that enter into the tool 304, arerounded on the outer surface 322 at a radius r. Let r be smaller thanthe tool inner diameter by some small margin. Then if the effectorchamfer profile falls inside a circle of diameter r, centered at thepivot point shown at Q in FIG. 35, then clearance is guaranteed for themounting is dismounting processes. An advantage of the shallow insertiondesign is that the tool can be pivoted off of the effector in thedismount process, and left in place as a target for the mount process,as discussed above. In certain applications however, a deeper insertionmay be desired, e.g., for imbalanced loads.

In the system 400 of FIGS. 36-42F, a linear motion is combined with arotational movement along a threaded shaft to pull the tool straightupward or downward off of the effector, which might be a more suitablemounting and dismounting action in some instances. Such a systemproduces a straight line upward or downward pulling motion, relative tothe effector, as the effector flies by in a linear motion. FIG. 36 showsan oblique view of the certain elements of the holder system, includingthreaded shaft 410 and split yoke members 412, 414. FIG. 38 shows a sideview of the system 400 as shown in FIG. 36, including an effector 402engaged with a tool 404. As further discussed below with reference toFIGS. 40A-40F, 41A-41F and 42A-42F, as the effector 402 travels along alinear path, the split yoke members 412, 414 engage the tool 404, andthe members 412, 414 rotate with the engaged tool. In particular oneyoke member 412 travels along the threads of the threaded member 410 andpulls the tool 404 away from the effector 402. A variable positionlocking member 416 keeps the yoke member 414 aligned with the yokemember 412. As shown in FIG. 37 (oblique view) and FIG. 39 (side view),one the yoke member 412 travels far enough along the threaded member 410to lift the tool 404 away from the effector 402. The tool 404 is therebyseparated from the effector 402. The mounting process would require thereverse steps.

FIGS. 40A-40F are oblique views of the process. FIG. 40A shows theeffector 402 coupled to the tool 404, and FIG. 40 F shows the effector402. As shown in FIGS. 40B-40E, as the effector 402 moves in a linearmotion (as shown at 5), the yoke member 412 rotates along the threadedshaft 410 to lift the tool 404 away from the effector 402, therebydecoupling the effector from the tool.

FIGS. 41A-41F show overhead views of the system shown in FIGS. 40A-40F,with FIG. 41A showing the effector 402 coupled to the tool 404, and FIG.41F showing the effector 402 decoupled from the tool. As may be see inFIGS. 41A-41F, the motion of the effector (as shown at 5) remainslinear. Again, the holder employs a split yoke, and the top yoke 412pivots on the threaded shaft 410 so that it rises as it pivots, and thebottom yoke's 414 motion is a simple pivot in the horizontal plane. Whenthe effector engages the holder, as the effector flies by the split yokeis forced to pivot, the top half 412 lifting upwards and forcing thetool off of the effector, while the bottom half 414 engages the effectorand helps to balance the lifting motion. FIGS. 42A-42F show side viewsof the system shown in FIGS. 40A-40F, with FIG. 42A showing the effector402 coupled to the tool 404, and FIG. 42F showing the effector 402decoupled from the tool. As may also be see in FIGS. 42A-42F, the motionof the effector (as shown at 5) remains linear.

FIG. 43 shows a diagrammatic abstract view of a system 60 in accordancewith an embodiment of the present invention, showing abstractrepresentations of components from above to show a layout of components.The system 60 includes a programmable motion device 62 (such as arobotic unit) that includes an end effector 72 for grasping and movingobjects. The end effector 72 on the programmable motion device 62 mayhave a reach as far as an arc as generally shown at 450. Within thisreach 450, the end effector 72 of the programmable motion device 62 mayreach destination bins 30, may reach perception station 29, may reachthe conveyor 22 and destination bins 56, and may reach a tool exchangingstation 52. The tool exchanging station 52 may be any of the above (orbelow) exchanging stations. The system may also include a touch inputscreen 23 as discussed above. The system further provides that theprogrammable motion device may identify an object in the bin 56 (usingthe perception unit 26 or by moving the object to the perception station29), select an appropriate acquisition device from the exchange station52, acquire the selected acquisition device from the exchange station52, and then grasp the identified object in the bin 56 for movement tothe destination bins 30. The system therefore provides that theprogrammable motion device may not only access the objects to beprocessed and the destination bins, but may also access a vacuum cupchanger station at which vacuum cups may be changed during processingbased on object identification information detected by the perceptionunit 26 or the perception unit 29.

If an object is identified by the perception unit 29 that requires adifferent vacuum cup than is currently attached to the end effector, theend effector may place the object back into the bin so that the objectmay be again grasped, but by a newly attached acquisition device. Incertain embodiments, the perception unit 26 may sufficiently identify anext object, and if the vacuum cup on the end effector needs to bechange the system may exchange a current vacuum cup to a desired one theis known to be a better acquisition unit for grasping the identifiedobject in bin 56.

The system may further seek to identify all objects in a bin 56, mayassociate each with an optimal vacuum cup, and may then seek to grasp,one at a time, each of the objects associated with a common vacuum cupprior to changing the vacuum cup on the end effector. In each of theseembodiments, the system itself identifies the need to change acquisitionunits, and then changes acquisition units by itself in the normal courseof operation.

FIGS. 44A and 44B diagrammatically show a plurality of exchange stations480 (e.g., of any of the above disclosed embodiments) that arepositioned such that an effector 482 may move through any of thestations 480, and exchange a tool 484 (FIG. 44A) for another tool 486(FIG. 44B) in a continuous or linear motion. FIGS. 44A and 44B show anarrangement of holders side by side forming a tool rack, to accommodatea selection of several tools. The arrangement shown is of serial pairs.The entire rack could be mounted on one turntable if desired toaccommodate a preferred direction of tool change motion. And/or theentire rack might be actuated to shift the desired holder into theeffector's planned path.

Other variants, include a suspension mechanism to allow for smoothmechanical interactions in the presence of small variations in position.Further variations would address possible latching mechanisms or detentmechanisms between the tool and effector, such as ball detents andbayonet mounts.

The above embodiments have employed the use of a straight line motion ofthe effector, but the invention may be adapted to other desired motions.FIGS. 45 and 46 illustrates this point with an embodiment thataccommodates a rotational movement of the end effector. FIG. 45, forexample, shows an exchange system 500 that includes a pair of retainingarm sections 508 mounted to a base 506. A tool 504 may be retainedbetween the arm sections 508 at a waist section 510 as shown in FIG. 45.FIG. 46 shows diagrammatically how the tool 504 may become decoupledfrom an effector 502 through a rotational movement as the effector movespast the exchange station.

In particular, the waist 510 of the tool will become engaged by the armsections 508, and the continuous movement of the effector (as shown at7) will cause the effector 502 to be pulled away from the tool 504 inmuch the same way as the tool was pulled from an effector or previouslydisclosed embodiments. Such a motion might be appropriate for aprogrammable motion device with few joints, incapable of making astraight line, or in a case where a rotating motion is faster than astraight line. This embodiment is shown in schematic form. As theeffector pivots about a horizontal pivot shown at the top of the figure,the tool engages the tool holder and is constrained to move horizontallyalong the tangent. There are a variety of ways of engaging andconstraining the tool's motion, as illustrated in previous embodiments.

In accordance with various embodiments, the invention provides a toolexchange mechanism comprising an effector interface, a tool interface,and a holder mechanism, where the interaction of the effector, tool, andholder produce the tool mounting and dismounting motions relative to thecontinuously moving effector. The coupling of the tool interface to theeffector interface may be magnetic. The coupling of the tool interfaceto the effector interface may be mechanical, such as by ball detents ora bayonet mount. The holder may include a mobile piece called thebracket that attaches to the tool. The bracket's connection may bemechanical or magnetic. The bracket's motion may be constrained toproduce a mounting or dismounting motion of the tool. The holder mayinclude fixed mechanical features that engage the tool, and themechanical features may constrain the tool's motion to produce amounting or dismounting motion. The holder may include a permanentmagnetic field to mount or dismount a tool, and may include a switchedmagnetic field, employing some combination of magnetic shunt, permanentmagnet, and/or electromagnet. The system may include an additionalmobile piece that mechanically engages the effector, while bracing theeffector against the forces used to dismount the tool.

In accordance with an embodiment, the invention may provide a pair oftool holder mechanisms, arranged in series, so that a single smoothmotion of the effector will pass through both mechanisms, dismountingone tool and mounting another. In further embodiments, two or more toolholder mechanisms, are arranged next to one another, so that theeffector may selectively pass through one holder to dismount the tool,then turn and pass through another holder to mount a different tool. Inaccordance with further embodiments one or more tool holder mechanisms,may be actuated to rotate so as to accommodate the desired motion of theeffector, or one or more tool holder mechanisms, actuated to present thedesired tool or tool holder to the effector. In accordance with afurther embodiment, the system may include an additional mechanism thatadvances a tool from one holder to the other holder. In accordance witha further embodiment, the tool and effector may be designed so that whenmounted, one piece is inserted into the other, at a depth and with aprofile such that the tool can be dismounted by pivoting about one ofthe contact points, without producing a collision.

In certain embodiments, a tool and effector may be designed so that whenmounted, one piece is inserted into the other, at a depth and with sucha profile that the tool cannot be dismounted by pivoting about one ofthe contact points, but must be pulled substantially straight.

Those skilled in the art will appreciate that numerous modifications andvariations may be made to the above disclosed embodiments withoutdeparting from the spirit and scope of the present invention.

What is claimed is:
 1. A method of changing a tool on a programmablemotion device, said method comprising the steps of: moving an attachmentportion of an end effector of the programmable motion device in acontinuous motion; while the attachment portion of the end effectormoves in the continuous motion, engaging one of: the attachment portionof the end effector with the tool, or the tool attached to theattachment portion of the end effector with an exchange system; andcontinuing to move the attachment portion of the end effector in thecontinuous motion to change a connection status of the attachmentportion of the end effector while the attachment portion of the endeffector moves in the continuous motion.
 2. The method as claimed inclaim 1, wherein the step of engaging involves engaging the attachmentportion of the end effector with the tool to thereby attach the tool tothe attachment portion of the end effector.
 3. The method as claimed inclaim 1, wherein the step of engaging involves engaging the toolattached to the attachment portion of the end effector with the exchangesystem to thereby detach the tool from the attachment portion of the endeffector.
 4. The method as claimed in claim 1, wherein the continuousmotion of the attachment portion of the end effector is linear.
 5. Themethod as claimed in claim 1, wherein the continuous motion of theattachment portion of the end effector is arcuate.
 6. The method asclaimed in claim 1, wherein the exchange system includes capturefeatures on the tool that engage control features on the exchangesystem.
 7. The method as claimed in claim 6, wherein the capturefeatures include protrusions on the tool.
 8. The method as claimed inclaim 6, wherein the capture features include at least one recession onthe tool.
 9. The method as claimed in claim 6, wherein the controlfeatures include guide rails on the exchange device.
 10. The method asclaimed in claim 6, wherein the control features include a graspingmechanism on the exchange device.
 11. The method as claimed in claim 10,wherein the grasping mechanism engages at least one recession on thetool.
 12. The method as claimed in claim 11, wherein the graspingmechanism separates the tool from the attachment portion of the endeffector by rotation.
 13. The method as claimed in claim 11, wherein thegrasping mechanism separates the tool from the attachment portion of theend effector by linear movement.
 14. The method as claimed in claim 1,wherein the tool is attachable to the attachment portion by magneticcoupling.
 15. The method as claimed in claim 1, wherein the tool isattachable to the attachment portion by mechanical coupling.
 16. Amethod of exchanging a tool on a programmable motion device, said methodcomprising the steps of: moving an attachment portion of the endeffector in a continuous motion; removing a first tool from theattachment portion of the end effector while the attachment portion ofthe end effector moves in the continuous motion; and attaching a secondtool to the attachment portion of the end effector while the attachmentportion of the end effector device moves in the continuous motion. 17.The method as claimed in claim 16, wherein the method further includesthe step of engaging, while the attachment portion of the end effectormoves in the continuous motion, the first tool attached to theattachment portion of the end effector with an exchange system.
 18. Themethod as claimed in claim 16, wherein the method further includes thestep of engaging, while the attachment portion of the end effector movesin the continuous motion, the attachment portion of the end effectorwith the second tool at the attachment portion of the end effector. 19.The method as claimed in claim 16, wherein the continuous motion of theattachment portion of the end effector is linear.
 20. The method asclaimed in claim 16, wherein the continuous motion of the attachmentportion of the end effector is circular.
 21. The method as claimed inclaim 16, wherein the exchange system includes capture features on thetool that engage control features on the exchange system.
 22. The methodas claimed in claim 21, wherein the capture features include protrusionson the tool.
 23. The method as claimed in claim 21, wherein the capturefeatures include at least one recession on the tool.
 24. The method asclaimed in claim 21, wherein the control features include guide rails onthe exchange device.
 25. The method as claimed in claim 21, wherein thecontrol features include a grasping mechanism on the exchange device.26. The method as claimed in claim 25, wherein the grasping mechanismengages at least one recession on the tool.
 27. The method as claimed inclaim 26, wherein the grasping mechanism separates the tool from theattachment portion by rotation.
 28. The method as claimed in claim 26,wherein the grasping mechanism separates the tool from the attachmentportion by linear movement.
 29. The method as claimed in claim 16,wherein the tool is attachable to the attachment portion by magneticcoupling.
 30. The method as claimed in claim 16, wherein the tool isattachable to the attachment portion by mechanical coupling.
 31. Amethod of changing a tool on a programmable motion device, said methodcomprising the steps of: moving an attachment portion of an end effectorof the programmable motion device in a linear motion; while theattachment portion of the end effector moves in the linear motion,engaging one of: the attachment portion of the end effector with thetool, or the tool attached to the attachment portion of the end effectorwith an exchange system; and continuing to move the attachment portionof the end effector in the linear motion to change a connection statusof the attachment portion of the end effector while the attachmentportion of the end effector moves in the linear motion.
 32. The methodas claimed in claim 31, wherein the step of engaging involves engagingthe attachment portion of the end effector with the tool to therebyattach the tool to the attachment portion of the end effector.
 33. Themethod as claimed in claim 31, wherein the step of engaging involvesengaging the tool attached to the attachment portion of the end effectorwith the exchange system to thereby detach the tool from the attachmentportion of the end effector.
 34. The method as claimed in claim 31,wherein the exchange system includes capture features on the tool thatengage control features on the exchange system.
 35. The method asclaimed in claim 34, wherein the capture features include protrusions onthe tool.
 36. The method as claimed in claim 34, wherein the capturefeatures include at least one recession on the tool.
 37. The method asclaimed in claim 34, wherein the control features include guide rails onthe exchange device.
 38. The method as claimed in claim 34, wherein thecontrol features include a grasping mechanism on the exchange device.39. The method as claimed in claim 38, wherein the grasping mechanismengages at least one recession on the tool.
 40. The method as claimed inclaim 38, wherein the grasping mechanism separates the tool from theattachment portion by rotation.
 41. The method as claimed in claim 38,wherein the grasping mechanism separates the tool from the attachmentportion by linear movement.
 42. The method as claimed in claim 31,wherein the tool is attachable to the attachment portion by magneticcoupling.
 43. The method as claimed in claim 31, wherein the tool isattachable to the attachment portion by mechanical coupling.
 44. Asystem for changing a tool on a programmable motion device, said systemcomprising engagement means for moving an attachment portion of an endeffector of the programmable motion device in a continuous motion, andwhile the attachment portion is moving, engaging the tool with one of anattachment portion of the end effector, or an exchange station tothereby change a connection status of the attachment portion of the endeffector while the attachment portion of the end effector moves in thecontinuous motion.
 45. The system as claimed in claim 44, wherein thecontinuous motion of the attachment portion of the end effector islinear.
 46. The system as claimed in claim 44, wherein the continuousmotion of the attachment portion of the end effector is circular. 47.The system as claimed in claim 44, wherein the exchange system includescapture features on the tool that engage control features on theexchange system.
 48. The system as claimed in claim 47, wherein thecapture features include protrusions on the tool.
 49. The system asclaimed in claim 47, wherein the capture features include at least onerecession on the tool.
 50. The system as claimed in claim 47, whereinthe control features include guide rails on the exchange device.
 51. Thesystem as claimed in claim 47, wherein the control features include agrasping mechanism on the exchange device.
 52. The system as claimed inclaim 51, wherein the grasping mechanism engages at least one recessionon the tool.
 53. The system as claimed in claim 52, wherein the graspingmechanism separates the tool from the attachment portion by any ofrotation.
 54. The system as claimed in claim 52, wherein the graspingmechanism separates the tool from the attachment portion by linearmovement.
 55. The system as claimed in claim 54, wherein the graspingmechanism includes a separator plate.
 56. The system as claimed in claim55, wherein the separator plate moves away from the attachment portion,together with the tool, as the separator plate advances along a threadedportion of the exchange system.
 57. The system as claimed in claim 44,wherein the tool is attachable to the attachment portion by magneticcoupling.
 58. The system as claimed in claim 44, wherein the tool isattachable to the attachment portion by mechanical coupling.